Method and apparatus for mechanically splicing optic fibers

ABSTRACT

A method and apparatus for mechanically splicing a pair of optic fibers or optic cables, the mechanical splice comprising: a ferrule having an axial capillary bore, the capillary bore configured to enclose the optic fibers at both ends of the ferrule; and cured epoxy disposed to secure together the ends of the optic fibers and to secure the optic fibers to an inside surface of the capillary bore, the ferrule optionally enclosed in a metal tube.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of Provisional PatentApplication No. 60/924,692 entitled “Compact and curable work stationfor fiber splice,” filed 29 May 2007 and incorporated by referenceherein in its entirety.

The U.S. Government has a paid-up license in this invention and theright in limited circumstances to require the patent owner to licenseothers on reasonable terms as provided for by the terms of Contract No.N68335-05-C-0308 awarded by the U.S. Department of the Navy.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to optic fiber splicing and, inparticular, to a method and apparatus for mechanically splicing opticfibers.

2. Description of the Background Art

Fusion splicing of optic fiber has been utilized in connecting opticfibers for a wide variety of optic devices, and has also been used forthe installation of fiber spans for telecommunications networks. In mostsuch application, the fusion splicing process is preferred over othermethods to achieve minimum insertion loss and long term reliability.However, for some applications a mechanical splicing process may presenta low-cost and convenient alternative that can accommodate many types ofoptic fibers. In particular, the mechanical splicing alternative isoften the preferred choice for applications in which the workenvironment presents a fire or explosive hazardous, such as in anaircraft, around oil stations, and in mines. In such hazardousapplications, the use of a high-voltage fusion splicing device istypically prohibited for safety reasons.

Optic fiber mechanical splicing devices are known in the prior art.Conventional mechanical splicers are typically based on a V-grooveseating configuration and, accordingly, are typically used only fortemporary fiberoptic connections because of associated unproven longterm reliability concerns. With respect to these reliability concerns,two primary long-term failure mechanisms have been identified in opticfiber components: material deterioration caused by prolonged humidityexposure and joint fatigue caused by extended thermal cycling inducedstress as well as relative movement between subcomponents. These twofailure mechanisms need to be addressed in the industry if thefundamental design objectives are to realize a twenty-five yearcomponent operation life and high reliability fiberoptic components.

The process of optic fiber splicing typically includes several manualsteps and involves extensive fiber handling among multiple pieces ofprocessing equipment. The fiber splicing preparation may include: fiberstripping, fiber tip cleaning, fiber cleaving, fiber aligning, fibersecuring and fiber splice packaging. Each of these process stepsrequires manual loading, unloading, and other manual process steps. Themanipulation and handling of the fibers throughout these process stepscompromises fiber strength and may lead to failure during subsequentuse.

What is needed is a method and apparatus using an integral precisionfiber alignment feature to easily and quickly produce a permanentmechanical splice for optic fibers.

SUMMARY OF THE INVENTION

In one aspect of the present invention, device for mechanically splicinga first optic fiber to a second optic fiber comprises: a ferrule havingan axial capillary bore, the capillary bore configured to enclose thefirst optic fiber at a first end of the ferrule and to enclose thesecond optic fiber at a second end of the ferrule; and cured epoxydisposed to secure an end of the first optic fiber to an end of thesecond optic fiber, the cured epoxy further disposed to secure the firstoptic fiber and the second optic fiber to an inside surface of thecapillary bore.

In another aspect of the present invention, an apparatus for splicing afirst optic fiber to a second optic fiber comprises: a first clampsecured to the first optic fiber; a second clamp secured to the secondoptic fiber, the first and second clamps for retaining an end of thefirst optic fiber against an end of the second optic fiber; and anultraviolet light source disposed to irradiate epoxy disposed betweenthe end of the first optic fiber and the end of the second optic fiber.

In another aspect of the present invention, a method for splicing opticfibers comprises the steps of: providing epoxy in a capillary bore of aferrule; placing an end of a first optic fiber against an end of asecond optic fiber in the epoxy inside the capillary bore; and curingthe epoxy.

The additional features and advantage of the disclosed invention is setforth in the detailed description which follows, and will be apparent tothose skilled in the art from the description or recognized bypracticing the invention as described, together with the claims andappended drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatical illustration of two optic fibers securedwithin a ferrule to form a mechanical splice shown in partial crosssection, in accordance with the present invention;

FIG. 2 is a cross-sectional diagrammatical illustration of themechanical splice of FIG. 1 showing a square capillary bore with fourmicro channels in the ferrule;

FIG. 3 is a cross-sectional diagrammatical illustration of analternative embodiment of the mechanical splice of FIG. 1 showing atriangular capillary bore with three micro channels in the ferrule;

FIG. 4 is a simplified diagram of one embodiment of a workstation havingan ultraviolet light module suitable for fabricating the mechanicalsplice of FIG. 2, in accordance with the present invention;

FIG. 5 is a diagrammatical illustration of the ultraviolet light moduleof FIG. 4 showing a cylindrical lens used to direct ultraviolet light;

FIG. 6 is a side view of a portion of an alternative embodiment of a UVmodule for the workstation of FIG. 4;

FIG. 7 is a diagrammatical illustration of the ultraviolet light moduleof FIG. 6 showing a reflector used to direct ultraviolet light;

FIG. 8 is a cross-sectional diagrammatical illustration of analternative embodiment of the mechanical splice of FIG. 1 showing anoval capillary bore with two micro channels in the ferrule;

FIG. 9 is a cross-sectional diagrammatical illustration of analternative embodiment of the mechanical splice of FIG. 1 showing anelongated capillary bore with one micro channel in the ferrule;

FIG. 10 is a cross-sectional diagrammatical illustration of analternative embodiment of the mechanical splice of FIG. 1 showing aferrule with an offset section;

FIG. 11 is a cross-sectional diagrammatical illustration of themechanical splice of FIG. 10 showing a triangular capillary bore havingrelaxed fabrication tolerances;

FIG. 12 is a cross-sectional diagrammatical illustration of analternative embodiment of the mechanical splice of FIG. 10 showing asquare capillary having relaxed fabrication tolerances;

FIG. 13 is an alternative embodiment of the mechanical splice of FIG. 1showing a metal tube enclosing the ferrule; and

FIG. 14 is a flow diagram explaining a process for fabricating themechanical splices of FIGS. 1 and 13.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplatedmodes of carrying out the invention. The description is not to be takenin a limiting sense, but is made merely for the purpose of illustratingthe general principles of the invention, since the scope of theinvention is best defined by the appended claims.

The present invention is a method and apparatus for efficientlyproducing a permanent, high reliability mechanism splice for optic fiberapplications. The disclosed mechanical splice design has been shown tosuccessfully pass standard industry environmental tests, includingvibration and thermal shock, to qualify for permanent installationapplication. Moreover, the disclosed design uses a glass seal technologyto permanently encapsulate components in a ferrule. For more demandingenvironmental conditions, or for application to fiber cable designs, ametal tube may be positioned and crimped to enclose the ferrule towithstand tensile forces in the optic fiber cable.

This feature provides high reliability even when humidity is a concern,for example, as exemplified by having successfully passed high pressureautoclave humidity testing of 120° C. and 100% relative humidity for aone week cycle. In addition, the disclosed mechanical splice design usesglass material with a coefficient of thermal expansion matched to theoptic fibers to mitigate or eliminate the progressive damage caused bythermal cycling, and to provide temperature stability performance.

The disclosed ferrule design provides passive precision self-alignmentfor an inserted optic fiber core and guided fiber insertion. The ferrulecomprises a material substantially transparent to ultraviolet radiationto allow for an integrated ultraviolet epoxy curing capability. Onedesign feature of the disclosed fiber guide ferrule allows for theinsertion of polyimide-coated fiber directly without the need to firststrip the hard resin buffer material layer. This approach is versatileand applies to a wide variety of the fibers found in military aviationincluding both multi-mode and single-mode fibers. The ferrule includes anon-circular capillary bore forming one or more axial micro channelswhen the optic fibers are inserted. The micro channels allow an outflowof excess epoxy and air bubbles when two optic fibers are inserted intothe epoxy contained in the ferrule. By using refractive index matchingof the epoxy and ferrule, and by applying an axial load to minimize thespace between the ends of the two optic fibers, an extremely low opticloss can be achieved between the fibers, to as little as 0.05 dB orless.

There is shown in FIGS. 1 and 2 an exemplary embodiment of a mechanicalsplice 20, in accordance with the present invention. The mechanicalsplice 20 functions to connect a first optic fiber 11 to a second opticfiber 13 by providing a permanent splice with a low fiber insertionloss. The mechanical splice 20 comprises a ferrule 21 with a capillarybore 23 axially extending between a first ferrule end 25 and a secondferrule end 27. As best seen in FIG. 2, the capillary bore 23 may have anon-circular cross-section in the general shape of a four-sided polygon,such as a trapezoid or square. The capillary bore 23 is configured toallow insertion of the first optic fiber 11 and the second optic fiber13 into the ferrule 21, as shown.

The specified size of the capillary bore 23 is large enough to allow thefirst optic fiber 11 and the second optic fiber 13 to be inserted intoand guided through the opposite ferrule ends 25 and 27 without breakageor binding. The size of the capillary bore 23 is further small enough toprovide for close retention of the optic fibers 11 and 13 inside thecapillary bore 23 and thus provide for precise relative alignment of therespective fiber cores when an end face 15 of the first optic fiber 11makes contact with an end face 17 of the second optic fiber 13. In theexample provided, the capillary bore 23 is shaped such that the opticfibers 11 and 13 contact the perimeter of the capillary bore 23 at up tofour circumferential regions and are thus restrained from misalignment.The ferrule 21 may include lead-in funnel-like or concave conicalopenings 19 at the ferrule ends 25 and 27, to provide improved fiberguidance when the optic fibers 11 and 13 are being inserted into theferrule 21.

The above configuration of the capillary bore 23 further provides microchannels 31, 33, 35, and 37 as internal volumes for retaining an epoxy41. As explained in greater detail below, the micro channels 31, 33, 35,and 37 also function as conduits to allow or enable excess epoxy 41 toflow out of the ferrule 21 as the optic fibers 11 and 13 are beinginserted into the ferrule 21. A thin layer 43 of the epoxy 41 isretained between the end face 15 of the first optic fiber 11 and the endface 17 of the second optic fiber 13 after the optic fibers 11 and 13have been inserted into the ferrule 21. The thin layer 43 of the epoxy41 thus functions to mechanically secure the end face 15 of the opticfiber 11 to the end face 17 of the optic fiber 13. The epoxy 41remaining in the micro channels 31, 33, 35, and 37 function to securethe outer surface of the first optic fiber 11 and the outer surface ofthe second optic fiber 13 to the ferrule 21.

In an exemplary embodiment, the index of refraction of the epoxy 41 issubstantially the same as, or closely matched to, the index ofrefraction of the cores of the optic fibers 11 and 13 to assure minimalinsertion loss of signal at the interface between the end face 15 andthe end face 17. The insertion loss may be further minimized bymaintaining a close tolerance on the size of the capillary bore 23 so asto provide precise alignment of the respective fiber optic cores.Preferably, the thermal coefficient of expansion of the epoxy 41 isclosely matched to the thermal coefficients of expansion of the opticfibers 11 and 13, and the thermal coefficient of expansion of thematerial used for the ferrule 21 is also closely matched to the thermalcoefficient of expansion of the optic fibers 11 and 13. This thermalcoefficient matching serves to minimize thermal stresses in themechanical splice 20 produced when the ambient temperature varies.

In an alternative exemplary embodiment, shown in the cross-sectionaldiagram of FIG. 3, a ferrule 51 comprises a capillary bore 53 having anon-circular cross sectional shape of a three-sided polygon, ortriangle. It should be understood that the shape of the capillary bore53 need not be an equilateral triangle, and that the vertices of thetriangular capillary may be rounded, as shown, in accordance withfabrication preference. The size of the capillary bore 53 is preferablyspecified such that the first optic fiber 11 and the second optic fiber13 can make contact with each other inside the ferrule 51 with preciserelative alignment of the respective fiber cores, as discussed above forthe ferrule 21. That is, the optic fibers 11 and 13 contact theperimeter of the capillary bore 53 at three circumferential regions toinsure the proper relative alignment.

The capillary bore 53 is further configured to provide micro channels55, 57, and 59 as internal volumes for retaining the epoxy 41, where thespecific sizes, shapes, and relative positions of the micro channels 55,57, and 59 depend upon the ferrule design and fabrication processes. Themicro channels 55, 57, and 59 similarly serve as conduits to allow orenable excess epoxy 41 to flow out of the ferrule 51 as the optic fibers11 and 13 are being inserted into the ferrule 51. The epoxy 41 splicesthe first optic fiber 11 to the second optic fiber 13 in the ferrule 51.

An exemplary embodiment of a mechanical splicing apparatus 60, or curingstation, for producing the mechanical splice 20 is shown in the diagramof FIG. 4. The apparatus 60 comprises a first detachable clamp 61removably mounted to a guide 39 on a base 65, and a second detachableclamp 63 slidably mounted to a guide 49 on the base 65. An ultravioletlight module 70 is mounted to the base 65 between the first detachableclamp 61 and the second detachable clamp 63. An elastic component, suchas a spring 69, is connected to the ultraviolet light module 70 and tothe second detachable clamp 63 as shown in the diagram. The ultravioletlight module 70 is configured to retain and irradiate a ferrule inposition for insertion of the optic fibers 11 and 13. In an exemplaryembodiment, the emplaced ferrule may be the ferrule 21, as shown, theferrule 51 described above, or either ferrule 111 or ferrule 121described below.

The first detachable clamp 61 may be used to secure and position thefirst optic fiber 11, and the second detachable clamp 63 may be used tosecure and position the second optic fiber 13, as shown in the diagram.Stripping, cleaning, and cleaving processes may be performed on theoptic fibers 11 and 13, if desired, while secured in the respectiveclamps 61 and 63 before attachment to the base 65. Both the firstdetachable clamp 61 and the second detachable clamp 63 can be movedalong the base such that the first optic fiber 11 and the second opticfiber 13 can be positioned for insertion into the emplaced ferrule 21while being held in the respective detachable clamps 61 and 63.

When the first detachable clamp 61 is fixed to the guide 39 on the base65 and the second detachable clamp 63 is allowed to slide along theguide 49, the spring 69 functions to provide a precisely controlled,predetermined force for urging the second detachable clamp 63 toward thefixed first detachable clamp 61, an action which causes the end 17 ofthe second optic fiber 13 to be controllably and precisely forcedagainst the end 15 of the first optic fiber 11 inside the ferrule 21.

The ultraviolet light module 70 comprises an ultraviolet light source,such as one or more UV lasers (not shown) or UV LEDs 71 (as shown). Someof the ultraviolet light from the UV LEDs 71 may be directly focusedonto the epoxy 41 in the ferrule by passing the light through aconverging cylindrical lens 73, as shown in greater detail in thediagram of FIG. 5. Other ultraviolet light from the UV LEDs 71 may bescattered from a reflector 75 to additionally irradiate other areas ofthe epoxy 41 upon reflection. The UV LEDs 71 may be disposed proximate aUV-transparent window 77 to allow for positioning of the ferrule 21proximate the ultraviolet light sources 71.

The ultraviolet light sources in the ultraviolet light module 70 arepowered by a power source, such as a rechargeable cell or battery 45(shown in FIG. 6). Control electronics 47 (shown in FIG. 6) may beprovided to control the exposure time and intensity of the UV LEDs 71 orUV diodes (if used). In an exemplary embodiment, a switch (not shown) isprovided to allow an operator to apply a pre-set amount of power to theUV LEDs 71 or to the UV laser diodes. The operating intensity of theultraviolet radiation may also be pre-set in the control electronics 47.It can be appreciated that, by providing UV LEDs as a source ofultraviolet light and a battery as a source of power, the mechanicalsplicing apparatus 60 may be configured as a compact, portablemechanical splicing device suitable for field applications.

FIGS. 6 and 7 illustrate an alternate exemplary embodiment of anultraviolet light module 80 that can be attached to the base 65 in placeof the ultraviolet light module 70. A ferrule, such as the ferrule 21,may be secured in the ultraviolet light module 80 by mounting in aV-shaped ferrule clamp 89. Ultraviolet light, provided by the UV LEDs71, may be reflected from a primary reflector, such as a cylindricalmirror 81, on to the epoxy 41 in the ferrule 21. The cylindrical mirror81 may be rotatable about a pivot 85 to allow for emplacement andremoval of the ferrule 21 from the ultraviolet light module 80. Strayultraviolet light may be reflected to the epoxy by a secondary reflector83 disposed proximate the ferrule 21, as best seen in the diagrammaticalrepresentation of FIG. 7. The ultraviolet LEDs 71 may be positionedagainst a UV-transparent glass plate 87 for alignment purposes.Operation of the ultraviolet LEDs 71 may be controlled and powered bythe control electronics 47 and the battery 45, as described above.

An alternative exemplary embodiment of a ferrule 91, shown in FIG. 8,may comprise a capillary bore 93 having an oval or elliptical shape. Thesize of the capillary bore 93 is specified such that each of the firstoptic fiber 11 and the second optic fiber 13 can make contact at twocircumferential regions, as shown, to provide for precise relativealignment of the respective fiber cores, as discussed above. In theconfiguration shown, a first micro channel 95 and a second micro channel97 are provided for outflow of excess epoxy 41.

In yet another exemplary embodiment, shown in FIG. 9, a ferrule 101 maycomprise a capillary bore 103 having an elongated non-circular shape.The capillary bore 103 provides a single micro channel 105 for excessepoxy 41. It should be understood that the inside configuration of thegreater portion of the capillary bore 103 closely approximates thegeometry of the outside surfaces of the optic fibers 11 and 13. The gapshown between the optic fiber 11 and the capillary bore 103 hasaccordingly been exaggerated to more clearly illustrate this feature.

FIG. 10 shows a cross-sectional view of an alternative exemplaryembodiment of a ferrule 111 (and a ferrule 121) having an offset section113 for providing precise fiber optic alignment with capillary boresthat have reduced fabrication tolerances. The offset section 113 has anoffset length “L” displaced at an offset distance 119, where the offsetlength L and the offset distance 119 may be determined as a function ofoptic fiber parameters and epoxy material properties. In an exemplaryembodiment, the offset distance 119 may be in the range of 20-30 μm.

FIG. 11 is a cross sectional view of the offset section 113 of theferrule 111 showing the optic fiber 13 emplaced in a triangularcapillary bore 115 having relaxed fabrication tolerances. Accordingly,the optic fiber 13 is forced against a micro channel 117 by virtue ofthe geometry of the offset section 113. In this configuration, the opticfiber 13 contacts an inside vertex of the triangular bore 115 at twocircumferential regions, in the direction of the offset section 113. Itcan be appreciated that the space between the optic fiber 13 and theinside surface of the triangular capillary bore 115 contains the epoxy41. Likewise, FIG. 12 shows a cross sectional view of an offset ferrule121 having a square capillary bore 123 with reduced fabricationtolerances. In this configuration, the optic fiber is urged in thedirection of the offset, to form a micro channel 125, and contacts theinside surface of the square capillary bore 123 at two circumferentialregions. It can be appreciated that the region between the optic fiber13 and the inside surface of the square capillary bore 123, which hasbeen exaggerated for clarity of illustration, contains the epoxy 41.

FIG. 13 shown an exemplary embodiment of a mechanical splice 140 forjoining jacketed optic fiber cable, such as a first optic cable 131 anda second optic cable 141. The mechanical splice 140 comprises aprotective metal tube 150 as an environmental enclosure for the ferrule,here shown as the ferrule 21, although it should be understood that anyof the ferrule 51, the ferrule 111, and the ferrule 121, or any othersuitable ferrule, can be used as well. The mechanical splice 140 furtherfunctions to withstand a tensile force that may be applied to either orboth the first optic cable 131 and the second optic cable 141 duringlaying, pulling, or other installation procedures, for example.

As typically configured in the present state of the art, the first opticcable 131 may comprise an optic fiber 133, a resin buffer layer 135, aflexible fibrous polymer 137, such as Kevlar®, and an outer jacket layer139, such as a plastic. The second optic cable 141 may similarlycomprise an optic fiber 143, a resin buffer layer 145, a flexiblefibrous polymer 147, and an outer jacket layer 149. The resin bufferlayer 135 and the resin buffer layer 145 are removed from the portionsof the optic fiber 133 and the optic fiber 143, respectively, to allowfor insertion into the ferrule 21, or another ferrule that may be used.The epoxy 41 secures the outer surface of the optic fiber 133 and theouter surface of the optic fiber 143 to the ferrule 21, and the thinlayer 43 of the epoxy 41 is retained between the optic fiber 133 and theoptic fiber 143, as described above for the mechanical splice 20.

An internal sleeve 151 is inserted between the resin buffer layer 135and the fibrous polymer 137, and another internal sleeve 151 is insertedbetween the resin buffer layer 145 and the flexible fibrous polymer 147.An outer sleeve 153 is positioned over the fibrous polymer 137 the firstoptic cable 131 such that a conical opening 157 in the outer sleeve 153encloses a flared end 155 of the internal sleeve 151. A portion of thefibrous polymer 137 is thus retained between the flared end of theinternal sleeve 151 and the conical opening of the outer sleeve 153.Similarly, another outer sleeve 153 is positioned over the fibrouspolymer 147 in the second optic cable 141 such that the conical opening157 in the other outer sleeve 153 encloses the flared end 155 of theother internal sleeve 151 to retain a portion of the fibrous polymer147.

A crimp 159 is formed in one end of the metal tube 150 at the outersleeve 153, and another crimp 159 is formed in another end of the metaltube 150 at the other outer sleeve 153, to secure the metal tube 150 tothe first optic cable 131 and to the second optic cable 141. It can beappreciated by one skilled in the relevant art that a tensile forceapplied to the first optic cable 131 is thus conveyed through thefibrous polymer 137 and through the metal tube 150 to the fibrouspolymer 147, and thus transferred to the second optic cable 141 withoutstressing either the first optic fiber 133 or the second optic fiber143. This configuration ensures that the first optic fiber 133 remainsspliced to the second optic fiber 143 after laying, pulling, or otherinstallation procedures have been performed on the first optic cable 131and the second optic cable 141.

The disclosed method of mechanical optic fiber splicing, using themechanical splices 20 and 140 as examples, can be explained withadditional reference to a flow diagram 160 in FIG. 14. A ferrule (i.e.,the ferrule 21, the ferrule 51, the ferrule 111, the ferrule 121, oranother suitably-configured ferrule) is obtained and the optic fibersare prepared by trimming and stripping as required, at step 161. If thesplice to be made is an optic fiber cable mechanical splice, or is afiber splice that may be subjected to harsh environments, at decisionbox 163, internal sleeves 151 and outer sleeves 153 are emplaced asdescribed above to retain the fibrous polymer material, and the metaltube 150 may be placed over one of the optic fibers, in step 165. If, atdecision box 163, the splice to be made is for loose-tube constructionoptic fibers, the metal tube may not be required and operation proceedsdirectly to decision box 167.

If the ferrule has been preloaded with epoxy, at decision box 167, theoptic fibers are inserted into the ferrule, at step 171. Preferably, thepreloaded ferrule has been stored by sealing in a light blocking andmoisture blocking packaging to prevent premature curing of the epoxy. Ifthe ferrule has not been preloaded with epoxy, at decision box 167, apredetermined quantity of epoxy may be injected into the ferrule, atstep 169, and then the optic fibers may be inserted at opposite ends ofthe ferrule, as in step 171.

A predetermined compressive axial force is applied to the optic fibersafter insertion to minimize the thickness of the layer of epoxy in theregion between the fiber ends, at step 173. Preferably, the magnitude ofthe force is restrained to prevent possible damage to the optic fibers.This compressive force may be applied and maintained by the spring 69,shown in FIG. 4. The epoxy 41 in the ferrule is cured, at step 175, byirradiation with a predetermined intensity of ultraviolet light for apredetermined time.

If the mechanical splice is to be used in loose-tube construction,rather than in a jacketed fiber cable application, at decision block177, the mechanical splice is complete, at step 179. If, on the otherhand, the mechanical splice is to used with jacketed optic fiber cable,the metal tube 150 is positioned to enclose the ferrule and the ends ofthe metal tube 150 are crimped onto the outer sleeves 153, in step 181,each internal sleeve 151 and outer sleeve 153 retaining therebetween aflexible fibrous polymer portion of the corresponding optic fiber cable.

It is to be understood that the description herein is exemplary of theinvention only and is intended to provide an overview for theunderstanding of the nature and character of the invention as it isdefined by the claims. The accompanying drawings are included to providea further understanding of various features and embodiments of themethod and apparatus of the invention which, together with theirdescription serve to explain the principles and operation of theinvention. Thus, while the invention has been described with referenceto particular embodiments, it will be understood that the presentinvention is by no means limited to the particular constructions andmethods herein disclosed and/or shown in the drawings, but alsocomprises any modifications or equivalents within the scope of theclaims.

1. A device for mechanically splicing a first optic fiber to a secondoptic fiber, said device comprising: a ferrule having a capillary bore,said capillary bore configured to enclose the first optic fiber at afirst end of said ferrule and to enclose the second optic fiber at asecond end of said ferrule; and epoxy disposed to secure the first opticfiber and the second fiber to a surface of said capillary bore; whereinsaid ferrule further includes at least one micro channel configured toenable excess said epoxy to flow out of said capillary bore; whereinsaid ferrule comprises an offset section; wherein said offset sectioncomprises an offset length of said ferrule displaced at an offsetdistance such that an end of the first optic fiber and an end of thesecond optic fiber are mutually aligned against said micro channel; andwherein said offset distance is approximately 10 to 200 μm.
 2. A devicefor mechanically splicing a first optic fiber to a second optic fiber,said device comprising: a ferrule having a capillary bore, saidcapillary bore configured to enclose the first optic fiber at a firstend of said ferrule and to enclose the second optic fiber at a secondend of said ferrule; a metal tube enclosing said ferrule; an internalsleeve disposed under a fibrous polymer layer enclosing the first opticfiber and between the fibrous polymer layer and the first optic fiber;an outer sleeve disposed over the fibrous polymer layer; and epoxydisposed to secure the first optic fiber and the second fiber to asurface of said capillary bore; wherein said ferrule further includes atleast one micro channel configured to enable excess said epoxy to flowout of said capillary bore; and wherein said outer sleeve has a conicalopening; said conical opening enclosing a flared end of said internalsleeve.
 3. The device of claim 2 wherein a portion of said fibrouspolymer layer is retained between said flared end of said internalsleeve and said conical opening of said outer sleeve; said flared end ofsaid internal sleeve and said conical opening of said outer sleeveconstituting a retaining device.